PALFINGER TAIL LIFTS

ASSEMBLY
INSTRUCTIONS
STANDARD TAIL LIFTS

LIFETIME EXCELLENCE
 Assembly instructions
for
PALFINGER Tail Lifts
Standard tail lifts

Dok: 07-500.99-04.10-03 Date: 25.09.2023

SNr: 2032342 Index: A25159
 Table of contents

1. About these assembly instructions..................................................7

1.1. Abbreviations used .................................................................. 7
1.2. Scope of delivery ..................................................................... 7
1.3. Enclosed documents ............................................................... 8
2. Important safety information.............................................................9
2.1. Personnel qualifications ........................................................... 9
2.2. Warning notices in these assembly instructions..................... 10
2.3. You must take these points into account during assembly ..... 11
2.3.1. General information.................................................... 11
2.3.2. Before starting assembly ............................................ 11
2.3.3. During assembly ........................................................ 12
2.3.4. During initial commissioning ....................................... 12
3. Required tools and auxiliary equipment ........................................13
4. Model line .........................................................................................14
4.1. Standard tail lift, overview ...................................................... 15
4.2. Tail lift with welded consoles and slide-in unit ........................ 16
4.3. Tail lift with bolted consoles and slide-in unit ......................... 17
4.4. Tail lift with platform and turning unit ..................................... 18
4.5. Tail lift without torque support ................................................ 19
4.6. Tail lift with torque support ..................................................... 20
5. Preparing for assembly ...................................................................21
6. Preparing the vehicle.......................................................................23
6.1. Removing projecting parts of the vehicle ............................... 24
6.2. Creating cut-outs for the lifting mechanism (optional) ............ 24
6.3. Reinforcing rear cross-member (optional) .............................. 25
6.4. Preparing vehicles with box bodies ........................................ 25

4
7. Installing the lifting mechanism ..................................................... 27
7.1. Pre-assembling the lifting mechanism .................................... 29
7.1.1. Tail lifts PTC 750 L - 1000 LLW .................................. 29
7.1.2. Tail lifts with laterally adjustable bolted consoles ........ 30
7.2. Attachment of the lifting mechanism to the vehicle ................. 33
7.2.1. Positioning lifting mechanism under the vehicle .......... 34
7.2.2. Positioning and fixing the installation aids
on the vehicle chassis ................................................ 35
7.2.3. Bolting the lifting mechanism to the installation
aid .............................................................................. 36
7.2.4. Positioning the stand tube / linkage mounts ................ 39
7.2.5. Fixing the console plates on the vehicle chassis ......... 41
7.2.6. Removing the installation aids .................................... 45
7.3. Installation of the hydraulic unit .............................................. 45
8. Establishing electrical connections ............................................... 46
8.1. Establishing the connection to the vehicle battery .................. 46
8.2. Establishing earth connection ................................................ 47
8.3. Connecting the acoustical signal generator ............................ 47
8.4. Installing and connecting the control unit /
the indicator light .................................................................... 48
8.4.1. Control unit connection ............................................... 48
8.4.2. Indicator lamp connection ........................................... 49
8.5. Attaching the control panel or Slimpanel ................................ 50
8.6. Connecting the manual cable switch (optional) ...................... 52
8.7. Radio remote control.............................................................. 53
9. Installing and connecting the platform .......................................... 54
9.1. Moving up and positioning the platform .................................. 55
9.2. Bolting the platform to the control rod..................................... 56
9.3. Bolting the platform to the tilt cylinders ................................... 57
9.4. Adjusting the tilt cylinders....................................................... 60
9.5. Installing tilt sensors............................................................... 61
9.5.1. Installing tilt sensor B15 .............................................. 61
9.5.2. Installing tilt sensor B15S ........................................... 63

5
 10. Adjusting and testing installed tail lift............................................64
10.1. Setting tilt sensor B15............................................................ 64
10.2. Adjusting tilt sensor B15S ...................................................... 65
10.3. Setting tilt switch B13 ............................................................ 67
10.4. Bleeding the hydraulic cylinders ............................................ 68
10.5. Bleeding the hydraulic cylinder (G < 450 mm) ....................... 69
10.6. Checking alignment of the platform
(only PTC 750 L, LLW) .......................................................... 70
10.7. Performing an oil level check ................................................. 71
10.7.1. Slide-in unit ................................................................ 71
10.7.2. Box, universal or turning unit ...................................... 72
10.7.3. Recommended hydraulic oils ..................................... 72
10.8. Lubricating the bearing .......................................................... 72
10.9. Checking bolted connections ................................................. 72
10.10. Checking hoses and cables ................................................... 72
10.11. Adjusting the pressure relief valve ......................................... 73
10.12. Adjusting the pressure switch of the hydraulic support
(optional) ............................................................................... 74
11. Final work .........................................................................................75
11.1. Attaching warning strips and type plate ................................. 75
11.2. Performing acceptance test as per control booklet ................ 76
12. Hydraulic diagrams..........................................................................77
12.1. Standard tail lift with four cylinders ........................................ 77
12.2. Standard tail lift with soft levelling .......................................... 78
12.3. Standard tail lift with two cylinder ........................................... 79
12.4. Standard tail lift with hydraulic stabilizer feet.......................... 80
12.5. Tail lift with hydraulic stabilizer feet C 750 L .......................... 81
12.6. Tail lift with hydraulic stabilizer feet C 750 S .......................... 82
12.7. Standard tail lift with hydraulic underrun bumper ................... 83

6
1. About these assembly instructions
These assembly instructions contain important information to ensure that the
PALFINGER Tail Lifts tail lift is safely and properly assembled.
Some texts in this manual have a special purpose and are marked as
follows:
• Listing
► Instruction for action

► Read these assembly instructions all the way through, particularly the
chapter “Important safety information" on page 9, before attaching the tail
lift.
► Observe all the generally applicable statutory and other binding European
and national regulations on accident prevention, handling hazardous
substances and on environmental protection.

1.1. Abbreviations used

Abbreviation/symbol Meaning
ETMA European Taillift Manufacturers Association

1.2. Scope of delivery

The scope of delivery of your PALFINGER Tail Lifts tail lift is based on the
model you ordered and any agreed special accessories.

7
 1.3. Enclosed documents
In addition to these assembly instructions, you will receive additional
documents with your PALFINGER Tail Lifts tail lift.
► Observed all documents enclosed with your ordered PALFINGER Tail
Lifts tail lift.
► In addition, you should also observe the operating instructions for the
PALFINGER Tail Lifts tail lift and all documents from the vehicle
manufacturer.
The following documents are enclosed with the PALFINGER Tail Lifts tail
lift:
• Assembly drawing (optional)
• Attachment report/attachment diagram (if requested)
• Control booklet
• Operating instructions
• Short operating manual
• Assembly instructions (short form)
• Underrun protection unit certificate
• Small and large test plate
• ETMA adhesive decal
• Type plate
• Assembly instructions for warning flags
• Electrical circuit diagram

8
2. Important safety information
The PALFINGER Tail Lifts tail lift has been built according to the state-of-
the-art and to recognised safety engineering rules. Nevertheless there is a
danger of personal injury and material damage if you do not comply with the
following general safety instructions and the warnings in these assembly
instructions.
► Read this assembly manual thoroughly all the way through, before
mounting the PALFINGER Tail Lifts tail lift.
► Keep the assembly instructions at hand in a good condition so that they
are always legible. Make sure that they are available to all responsible
fitters at all times.
► Always ensure that these assembly instructions and the supplied
documents are always passed on along with the PALFINGER Tail Lifts
tail lift to third parties.

2.1. Personnel qualifications

The assembly and commissioning of the PALFINGER Tail Lifts tail lift
require systematic knowledge of mechanical, electrical, hydraulic systems as
well as familiarity with the associated specialist terms. Consequently to
ensure operational safety these activities may only be executed by trained
and authorised specialists, who have been instructed in safety engineering
aspects, or by an instructed person working under the supervision of a
specialist.
A specialist is a person who, due to their specialised training, knowledge and
experience, as well as knowledge of the applicable regulations, can evaluate
the tasks assigned to them, recognise possible dangers, and implement
suitable safety measures. A specialist must comply with the applicable
technical rules.

9
 2.2. Warning notices in these assembly instructions
In these assembly instructions safety instructions precede a procedure which
incurs risks of personal injury or material damage.
Warnings are structured as follows:

SIGNAL WORD!
Description of type and source of the danger!
Description of consequences of non-observance.
► Description of measures for avoiding danger.

• The warning triangle indicates a risk of fatal or severe injuries.

• The signal word indicates the severity of the danger. The signal words
have the following meanings:

Signal word Meaning

DANGER! Indicates an imminent, major hazard that is certain to
result in serious injury or even death if the hazard is not
avoided.
WARNING! Indicates a potential hazard that may result in serious
injury or even death if the hazard is not avoided.
CAUTION! Indicates a potentially hazardous situation which, if not
avoided, may result in moderate or minor injury or
property damage.
Note: If you do not observe this information, the assembly
process may be adversely affected.

• The paragraph “Type and source of hazard” describes the nature and
source of the danger.
• The paragraph “Consequences” describes possible consequences of
ignoring the warning.
• The “Avoidance of hazard” paragraphs indicate how to avoid the danger.
It is essential that the measures to avert danger are complied with.

10
2.3. You must take these points into account during
assembly
2.3.1. General information
► Observe these assembly instructions and in particular all the safety
instructions.
► Structural modifications on the tail lift may only be performed by
PALFINGER Tail Lifts contract workshops. You can find your nearest
authorised workshop in the location search at www.palfinger.com under
“ales and service search”.
► Only use PALFINGER Tail Lifts original parts during assembly work.
► Observe all applicable accident prevention regulations.
► Observe the vehicle manufacturer's attachment guidelines.
► Observe the respectively applicable general attachment report
(attachment diagram) from PALFINGER Tail Lifts.
► Make sure that any welding work is only performed by certified welders. It
is essential to comply with the vehicle maker's specifications as well as
the applicable standards and regulations for welding work.

2.3.2. Before starting assembly

► Check the compatibility of the vehicle and the tail lift before assembly.
► Refer to the chapter “Test by the assembler before assembly” in the
control booklet.
► Observe the attachment report (attachment diagram).
► Before starting assembly, read the safety instructions in the operating
instructions, especially the chapter "Care and maintenance".
► Observe the additional assembly instructions that were included with the
respective components (e. g. camera system).
► Place the vehicle on a level and firm surface for assembly and align the
vehicle so it is also level.
► If the vehicle has air suspension, deactivate this.
► Always disconnect the battery and the ABS system before assembly.

11
 2.3.3. During assembly
► When connecting the hydraulic parts, ensure that the connections are
clean and that no contamination can get into the hydraulic circuit.
► Make sure that the PALFINGER Tail Lifts tail lift and its moving parts, the
coupling, the brake system, the oil lines, the pneumatic lines and the
cabling of the vehicle are not damaged.
► Do not apply any overpressure to the functions lift/lower, open/close,
retract or extend before the assembly is entirely completed.

2.3.4. During initial commissioning

► Only operate the tail lift when the vehicle's superstructure is fitted. If you
operate the tail lift without its body, there is a risk that the pistons of the
lift cylinders will fall out if the lifting height is too high, resulting in personal
injury and material damage.
► During initial commissioning of the PALFINGER Tail Lifts tail lift, check
whether all safety and warning features are available and functional.
• Warning strips
• Warning lights
• Roll bar
► Carry out an acceptance test according to the control booklet (see
chapter 11.2, page 76).

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3. Required tools and auxiliary equipment
To assemble your PALFINGER Tail Lifts tail lift you will need the following
tools and auxiliary equipment:

Tools
Wrench size in mm: 6, 8, 10, 13, 15, 17, 19, 21, 36, 41, 46, 50, 60, 65, 70
Set of Allen keys up to 24 mm
Torque wrench 25 up to 400 Nm
Socket wrench 4, 6
4x screw clamps
Peening tool
Hand-held electric drill
Spiral drill up to 14 mm diameter
Crimping tool for cable lugs (16 mm2, 25 mm2, 35mm2)
Insulation stripper
Side cutter
TORX® screwdrivers
Mallet
Impact wrenches size in mm: 46, 50, 60, 65
Locking pliers for external rings A2

Auxiliary equipment
Installation aid (installation device)
Stop bracket
Marker
Tape measure
Lifting equipment (e.g. forklift, pallet truck)
Battery terminal grease
Lubricant grease for bearing pins
Grease gun

13
 4. Model line
Below a list of standard version models of PALFINGER Tail Lifts tail lifts.
The following models are available:

C 1000 S – C 3000 S
C 1000 LD – C 2500 L
C 1500 SZ – C 2500 SZ
C 2000 SK – C 2500 SK
C 750 SPLD SPRD – C 1000 SPL SPR
C 750 LD – C 1000 L
C 1000 ML – C 1500 ML
C 1000 ML PRO – C 1500 ML PRO
C 750 S
C 500 LD – C 750 LD
C 750 SPL SPR
C 1500 LX – C 2000 LX
PTC 750 L
PTC 750 S
PTC 1000 LLW

The following general drawings show the structure of the PALFINGER Tail
Lifts tail lift and of the individual sub-assemblies.

14
 4.1. Standard tail lift, overview

2
6

4
5
9 8 4 7 6

Figure 1: Standard tail lift, overview

1 Operating unit (Slimpanel) 6 Tilt cylinder

2 Stand tube 7 Torsion frame, control rod
3 Hydraulic unit and controller 8 Lift cylinder
(in stand tube)
4 Hydraulic prop 9 Platform
5 Underrun protection

15
 4.2. Tail lift with welded consoles and slide-in unit
6

3 2 1
Figure 2: Tail lift with welded consoles and slide-in unit

1 Welded console plates 4 Tilt cylinder

2 Stand tube 5 Lift cylinder
3 Underrun protection 6 Torsion frame

16
 4.3. Tail lift with bolted consoles and slide-in unit
6

3 2 1

Figure 3: Tail lift with bolted consoles and slide-in unit

1 Bolted console plates 4 Tilt cylinder

2 Hydraulic unit (in stand tube) 5 Lift cylinder
3 Underrun protection 6 Torsion frame

17
 4.4. Tail lift with platform and turning unit

4 3

Figure 4: Tail lift with platform and turning unit

1 Platform 4 Underrun protection

2 Turning unit 5 Tilt cylinder
3 Bolted console plates 6 Lift cylinder

18
 4.5. Tail lift without torque support

6 5 4

Figure 5: Tail lift without torque support

1 Platform 5 Linkage mount

2 Control rod, stroke 6 Underrun protection
3 Lift cylinder 7 Control rod, tilt
4 Universal unit 8 Tilt cylinder

19
 4.6. Tail lift with torque support

2
4

6 5
Figure 6: Tail lift with torque support

1 Platform 5 Linkage mount

2 Tilt cylinder 6 Underrun protection
3 Lift cylinder 7 Trailer hitch
4 Universal unit

20
5. Preparing for assembly
This chapter contains basic information about what you need to remember
when preparing to assemble your PALFINGER Tail Lifts tail lift. This
information relates to the "standard" versions of all PALFINGER Tail Lifts
tail lift models.
► First read these assembly instructions through and then follow them step-
by-step.
► You should also observe the operating manual for your PALFINGER Tail
Lifts tail lift and in particular all the safety instructions.
► Perform all the preparatory work properly and carefully.
► If in doubt or if you have any questions, contact PALFINGER Tail Lifts
before proceeding with work.

CAUTION!
Incorrect assembly can result in damage to the vehicle and the tail lift!
The vehicle and the tail lift may be damaged if you incorrectly assemble the
tail lift.
► It is essential to comply with the vehicle maker's guidelines for mounting
attachments.
► It is especially important to comply with the tail lift's maximum permitted
rated load and the axle spacing for the tail lift.

► Before starting assembly work, please check the following points:

• Is the vehicle suitable for mounting the PALFINGER Tail Lifts tail lift?
Do the vehicle dimensions correspond to those of the PALFINGER
Tail Lifts tail lift?
• Have the attachment report (attachment diagram) been provided in
accordance with your ordered PALFINGER Tail Lifts tail lift type?
• Is the delivered PALFINGER Tail Lifts tail lift consistent with your
order and have all parts required for assembly been correctly delivered
(see parts list)?
• Is the operating voltage of the vehicle battery appropriate for the rated
voltage of the PALFINGER Tail Lifts tail lift?
• Is the capacity of the vehicle battery sufficient for the Palfinger Tail
Lifts tail lift?
The following capacities are required:

Load bearing capacity 12 V 24 V

500 to 1000 kg 142 Ah 105 Ah
1500 to 3000 kg 180 Ah 180 Ah

21
 • Are all required tools and auxiliary equipment available? Are any
another special tools required?
• Do cut-outs have to be made for the lifting mechanism?
• Should a seal be installed in vehicles with a box body without rear
doors? If this is the case, the platform must be set at a distance
(procedure: see note on page 37).
• Is the use of trailers planned? If yes, sufficient space for the trailer
coupling must be available and the free movement of the drawbar must
be ensured.
When all these points have been checked off, you can start with the
assembly or pre-assembly (for PTC 750 L - PTC 1000 LLW) of your
PALFINGER Tail Lifts tail lift. Assembly consists of several steps, which are
described in more detail on the following pages. They include:
• preparation of vehicle or vehicle chassis (see chapter 6, page 23)
• pre-assembling/assembling lifting mechanism (see chapter 7, page 27)
• establishing electrical connections (see chapter 8, page 46)
• installing and connecting the platform (see chapter 9, page 54)
• adjusting and testing the platform (see chapter 10, page 64)

22
6. Preparing the vehicle
Before mounting the PALFINGER Tail Lifts tail lift on your vehicle, you must
prepare the vehicle accordingly. The specific steps vary according to the
intended purpose and the vehicle type.

Technical parameters
► Determine the most important technical parameters for the attachment of
your tail lift.
These include:
• the installation height
• the required projection
• the position of the platform and lifting mechanism under the vehicle
• the fixing of installation aids
• the required space for the lifting mechanism for any offset rear lights
• the thickness of the vehicle's rear cross-member and any cut-outs
required in the lower tail chassis
To prepare the vehicle for installation of the PALFINGER Tail Lifts tail lift,
the following steps must be completed:
• removing projecting parts of the vehicle (see chapter 6.1, page 24)
• if necessary, making any necessary cut-outs for the lifting mechanism and
reinforcing these (see chapter 6.2, page 24)
• reinforce the rear cross-member, if required (see chapter 6.3, page 25)

Vehicles with box bodies

Additional steps may be necessary for vehicles with box bodies or flat beds
(with or without gates) (see chapter 6.4, page 25). These include:
• mounting the supplied connecting profile on the vehicle,
• preparing and mounting bridging profiles/spacers,
• mounting the optional sealing system.

23
 6.1. Removing projecting parts of the vehicle

CAUTION!
Damage and loss of components!
If you do not safely store the removed components in a dry place, they may
be damaged or lost.
► Remove the interfering components carefully from the vehicle.
► Store the removed components in a secure, dry place.

► Check the mounting position of the lifting mechanism using the

attachment report (attachment diagram).
► Remove all interfering components from the vehicle. These may include:
• rear lights
• reversing lights
• license plate
• spare wheel holder
• Pallet carrier
• parts of the vehicle exhaust
• underrun protection.
► Store the removed components in a secure, dry place.
Components that are not compatible with PALFINGER Tail Lifts tail lift may
not be reinstalled.
► Consult your vehicle maker to find alternative solutions for incompatible
components.

6.2. Creating cut-outs for the lifting mechanism

(optional)
For most applications you will not need any special cut-outs for the lifting
mechanism. If this is necessary, however, you can obtain the dimensions for
the cut-outs from the attachment report (attachment diagram) from
PALFINGER Tail Lifts.
► Transfer the dimensions or the lifting mechanism cut-outs from the
attachment diagram to the real cross-member.
► Create the cut-outs according to the attachment mounting diagram and
reinforce them.
► Seal the blank body parts with rust protection and repaint them. Observe
the vehicle manufacturer's superstructure guidelines.

24
 6.3. Reinforcing rear cross-member (optional)
Your truck's rear cross-member must be rated for your ordered type of
PALFINGER Tail Lifts tail lift. The rear cross-member of your vehicle should
be capable of carrying twice the load capacity of your PALFINGER Tail Lifts
tail lift (e.g. about 2000 kg for a 1000K tail lift).
If the rated load of the rear cross-member is insufficient for the ordered
PALFINGER Tail Lifts tail lift, you may have to reinforce it.

6.4. Preparing vehicles with box bodies

Mounting the sealing system

► A sealing system can be ordered from PALFINGER Tail Lifts and pre-
installed for vehicles with box bodies. The sealing system is mounted
according to the special assembly instructions supplied.

Note:
We recommend installing a sealing system before installing the tail lift.

Box bodies with doors

To avoid damage to box body doors, you must attach spacers and bridging
profiles. You must then abut the control rod of the torsion frame to the
superstructure end with the bridging profile when the doors are open.

Bridging profile

Figure 7: Bridging profile with cut-outs for door hinges

25
 ► Prepare the spacers for the lifting mechanism area (if necessary).
► Fix the spacers to the door.
► Create a bridging profile (e.g. a square tube with rounded edges
60x40x3).
► Mount the bridging profile over the entire loading area width.

26
7. Installing the lifting mechanism
Attachment of the lifting mechanism to the vehicle chassis depends on the
type of console plates used. Tail lifts with the following console pates can be
ordered from PALFINGER Tail Lifts:
• welded consoles
• bolted consoles

ATTENTION!
Damage to the slide-in unit during welding work!
If you do not pull out the slide-in unit before starting welding work on the
stand tube, it may be damaged.
► Pull out the slide-in unit before starting welding work on the stand tube.
► Protect the slide-in unit from possible damage caused by welding.

The installation sequence differs according to the type of console plates

used.
The welded consoles are attached in advance by PALFINGER Tail Lifts to
the lifting mechanism. The customer notifies PALFINGER Tail Lifts of the
required distances between the console plates and these cannot be
subsequently changed. The lifting mechanism is attached with the console
plates to the vehicle chassis.
The bolted consoles are first adjusted on the lifting mechanism to the chassis
size and then fixed. Together with the lifting mechanism, they are then
attached to the vehicle chassis. The long holes in the bolted consoles make
transverse adjustments possible (not on PTC, SKN).

Note:
For tail lifts with bolted consoles, we recommend fitting the bracket plates
to the lifting mechanism first (see chapter 7.1.2, page 30) and then
carrying out the assembly of the lifting mechanism on the vehicle

Adapters are available for the fitting of the tail lift on vehicles with frames
made of double-T beams. These are attached to the vehicle chassis with
clamping pieces (claws) (see Figure 8, page 28).

27
 Vehicle chassis
Adapter

Claws

Figure 8: Attachment with adapters and clamping pieces (claws)

28
 7.1. Pre-assembling the lifting mechanism
7.1.1. Tail lifts PTC 750 L - 1000 LLW
► Fit the console plates to the linkage mounts with the M14 bolts provided.
When doing so, observe the prescribed tightening torques (see table on
page 31).
► Determine the console inner dimension and compare it with the chassis
width of the vehicle.
If the console inner dimension exceeds the chassis width:
► When assembling, use spacer plates between the linkage mount and the
screw-on plates to reduce the console's internal dimension to the width
of the chassis (exemplary presentation in Figure 9). The number of
spacer plates required can be found in the table in the attachment report
(attachment diagram).

Figure 9: Spacer plates (exemplary presentation)

1 Vehicle chassis 3 Spacer plates

2 Mounting plate 4 Linkage mount

29
 7.1.2. Tail lifts with laterally adjustable bolted consoles

2
5

6 4

1
2

8
7

Figure 10: Pre-assembly with laterally adjustable bolted consoles

1 Stand tube 5 hex. nuts

2 console plate 6 Console plate pocket

3 hooks 7 Safety clips

4 Press-in screws M20x1.5 8 ground cable (option)

(pressed in when the tail lift is
delivered)

► Optional (when using a ball head coupling and with the C 3000 S):
Connect the locking clamps (7) to the console plate (2) (see Figure 10).

Note:
First clamp the safety clips (7) into the console plates (2). Only then attach
the console plates to the stand tube. When the console plates are
attached, the safety clips can no longer be inserted.

► Clamp the safety clips (7) into the console plates (2).
► Thread the console plate pockets (2) with the bolts (4) and the hook (3)
into the console plate pockets (6).

30
► Screw the console plate pockets (2) with the bolts (4) and the hexagon
nuts (5) in the console plate pockets (6).
► Align the two console plates corresponding to the frame width and pre-
tighten the hex. nuts.
► Mount the lifting mechanism as described from the chapter “Attachment
of the lifting mechanism to the vehicle”, page 33.
► Tighten the hexagon nuts (5).
► Optional (when using a ball head coupling and with the C 3000 S): Screw
the locking clamps (7) by means of the hex. screw and nut to the stand
tube (1).
► Note the following tightening torques.

Bolts Tightening torque

Press-in bolt M20x1.5 - St10.9 400 Nm

Bolt M14x1.5 - St10.9 190 Nm

Bolt M10 - St8.8 50 Nm

The bolts must be regularly retightened regularly:

• after 3 weeks in operation
• after 3 months in operation
• check and if necessary retighten half-yearly.

Reinforcement of the bolted consoles on C 1000 S and C 1500 L

On the C 1000 S and C 1500 L tail lifts, the console plates must be reinforced
with the mounting kit (item no. 2030247) (see Figure 11, page 32).

31
 1 2 3 4
Figure 11: Reinforcement of the console plates

1 console plate 3 T-profile

2 Plate 4 Bolt/nut M10

► Place the plates against the console plates on both sides and hook them
behind the T-profiles (see Figure 11).
► Screw the plates to both console plates.

32
7.2. Attachment of the lifting mechanism to the vehicle
To assist in the installation of the lifting mechanism of your PALFINGER Tail
Lifts tail lift, you can on request obtain special installation aids (see
Figure 12, page 33). This installation aids support you in mounting the lifting
mechanism.
The installation aids each have four lugs with holes of different sizes. When
the lifting mechanism is positioned under the vehicle and the torsion frame
is raised, the control rods of the torsion frame can be bolted to the respective
matching lugs. The installation aids attached to the loading area then hold
the torsion frame in position.

Figure 12: Installation aids

The following steps are required when installing with installation aids:
• positioning the lifting mechanism under the vehicle (see chapter 7.2.1,
page 34)
• position and fix the installation aids on the vehicle chassis (see
chapter 7.2.2, page 35)
• bolting the lifting mechanism to installation aids (see chapter 7.2.3,
page 36)
• positioning the stand tube (see chapter 7.2.4, page 39)
• fix lifting mechanism with console plates to vehicle chassis (see
chapter 7.2.5, page 41)
• mounting the hydraulic unit (see chapter 7.3, page 45)
• removing installation aids (see chapter 7.2.6, page 45)

33
 7.2.1. Positioning lifting mechanism under the vehicle

► Raise the lifting mechanism with suitable lifting equipment such as a

forklift truck or with a pallet truck, for example.

Note:
We recommend lifting the lifting mechanism on the pallet on which it is
delivered and positioning it under the vehicle. This will prevent you from
damaging the coating of the lifting mechanism.

Figure 13: Positioning the lifting mechanism

► Carefully position the lifting mechanism under the vehicle (see Figure 13).
► Detach the cables and hoses and feed them through the openings
provided in the vehicle chassis.
► Carefully raise the lifting mechanism and move it into the installation
position.
► Maintain the installation position with the lifting equipment until the lifting
mechanism is finally fixed to the vehicle chassis.

34
7.2.2. Positioning and fixing the installation aids on the vehicle
chassis

CAUTION!
Danger of injury!
If you incorrectly position the installation aids or do not fix it correctly, the
torsion frame may fall. Personal and material damage are possible.
► Make sure that the installation aids are correctly positioned and properly
fixed.

Figure 14: Positioning the installation aids

► Lay the installation aids on the loading area.

► Align the side of the installation aids so that the appropriate shackle rests
against the side of the raised control rod and can be bolted securely.
► Securely fix the installation aids to the vehicle chassis with, for example,
screw clamps.

35
 7.2.3. Bolting the lifting mechanism to the installation aid
► Make sure that the lifting mechanism is in its final installation position.
► With a sealing system, fit 25 mm spacers to ensure the correct distance
between the torsion frame control rods and the vehicle chassis (see note
on page 37).

Note:
We recommend installing a sealing system before installing the tail lift.

► Secure the position of the lifting mechanism to the vehicle chassis with
screw clamps.
► Lay the cables and hoses under the vehicle chassis. Route the cables and
hoses so that they cannot be damaged by movements of the tail lift or the
vehicle.
► Bolt the lifting mechanism with the installation aid (see Figure 15).
► Check the alignment to the vehicle body. Both control rods of the torsion
frame must be flush with the rear-cross member.

Installation aids

Control rod of the torsion frame Rear cross-member

Figure 15: Bolting the lifting mechanism and installation aids

36
 Note:
When attaching a plastic-coated platform:
► Place 2 mm plates between the control rods of the torsion frame and
the superstructure as spacers (see Figure 16).
This is necessary because otherwise the platform will stand too high after
assembly.
When attaching a sealing system to the box body:
► Place 25 mm spacers between the control rods of the torsion frame and
the superstructure.
This is necessary so that there is enough space for the sealing system
between the superstructure and the closed platform.

Installation aid

Pin

2 mm plate
Rear cross-
member

Control rod

Figure 16: 2 mm spacer plates for assembly of a coated platform

► Check that the lifting mechanism is exactly centred at the sides (see
Figure 17 and Figure 18, page 38).

37
 Figure 17: Check the central position of the lifting mechanism (1)

Figure 18: Check the central position of the lifting mechanism (2)

38
 7.2.4. Positioning the stand tube / linkage mounts
► Position the stand tube / linkage mounts at a height according to the
specified dimensions in the attachment report (dimensions "F", "G" and
"H" in the attachment diagram, see Figure 19).

Note:
The dimensions "F", "G" and "H" must be strictly observed during
assembly!

Stand tube

Linkage mount

Figure 19: Positioning the stand tube / linkage mounts

► Bring the stand tube / linkage mounts into a horizontal position (aligned
with the vehicle body).
► Secure the stand tube / linkage mounts to the vehicle frame in this position
with screw clamps (see Figure 20, page 40).

39
 Console plate Subframe loading floor Vehicle chassis

Stand tube

Figure 20: Positioning the stand tube

► Check the lateral position of the lifting mechanism again.

40
7.2.5. Fixing the console plates on the vehicle chassis
Determining the arrangement, number and size of the fixing holes

Depending on the type of tail lift, the permitted payload and the presence of
a ball head coupling, the attachment of the console plates to the vehicle is
subject to different loads during operation. The size, quality and number of
fixing bolts and their distance from each other must be chosen accordingly.

DANGER!
Dangers due to an improperly fixed tail lift!
If the console plates of the tail lift are fastened to the vehicle with too few or
too weakly dimensioned bolts, or if the bolts are too close together, the
bolted connection cannot absorb the torque exerted by the tail lift during
operation.
The tail lift can come loose. There is a risk of fatal injury as well as material
damage.
► Observe the following table for the size, quality and number of fixing
bolts.
► Place the fittings at a sufficient distance from each other.

DANGER!
Danger of a tail lift coming loose if overly large holes are used!
When using a hole pattern in the vehicle chassis, take care not to use holes
that are too large. 16 mm holes are too large for 14 mm bolts! The tail lift
can later shift and become loose if too large holes are used.
► Use only matching holes in the hole pattern of the frame (e.g. 14 mm
holes for 14 mm bolts).
► Re-drill through the frame if the holes in the frame hole pattern are too
large.

Note:
Some vehicle manufacturers have special requirements for the attachment
of the tail lift to the vehicle.
► Observe the vehicle manufacturer's installation guidelines for bolting
the console plates to the vehicle chassis.

41
 Number of
bolts per Tightening
Type of tail lift Bolt type
console torque
plate
C 500 SD
C 500 SPLD/SPRD
C 750 SPL/SPR
C 750 S
C 500 LD
C750 L 6 M12x1.5 – St10.9 110 Nm
C 750 LG 4 M14x1.5 - St10.9 190 Nm

C 750 LD
C 1000 ML (PRO)
PTC 750 L
PTC 750 S
PTC 1000 LLW
PTC 750 L
(with ball head coupling)

PTC 750 S 6 M14x1.5 - St10.9 190 Nm

(with ball head coupling)

PTC 1000 LLW

(with ball head coupling)

C 750 SPLD/SPRD
C 1000 SPL/SPR
C 1000 LD
6 M14x1.5 - St10.9 190 Nm
C 1000 L
C 1500 L
C 1500 ML PRO

42
 Number of
bolts per Tightening
Type of tail lift Bolt type
console torque
plate
C 1500 S
C 1500 LX –
C 2000 LX
C 1500 SZ
C 2000 LZ 10 M14x1.5 - St10.9 190 Nm
C 2000 SK –
C 2500 SK
C 2000 L – C 2500 L
C 2000 LX PTG
C 2500 S
C 2500 SK
C 2500 SD 14 M14x1.5 - St10.9 190 Nm

C 2500 SZ
C 3000 S

► Determine the arrangement and number of mounting holes for the console
plates on the vehicle chassis.
Please refer to the table above.
► Determine the size of the fixing holes.
Observe the vehicle manufacturer's attachment guidelines.
► Mark out the holes.
When using a hole pattern on the vehicle chassis:
► Make sure that the diameter of the bolts corresponds to the diameter of
the holes on the vehicle chassis.
Figure 21, page 44, shows an example of a possible arrangement of the
fittings of a console plate.

43
 Subframe loading floor Fittings Console plate
Vehicle chassis

Figure 21: Bolting console plates

Drilling the holes, screwing the console plates to the vehicle frame
► Drill the holes (see Figure 22). Drill through the frame if there is no frame
hole pattern.

Figure 22: Drill the holes

44
► Bolt the console plates to the vehicle chassis (see Figure 21, page 44).
Observe the tightening torques in the table on page 42.

7.2.6. Removing the installation aids

CAUTION!
Danger due to uncontrolled swinging down of the torsion frame!
Because there is still too little oil in the lift cylinders, the torsion frame can
swing down uncontrollably when its control rods are released from the
installation aids. There is a danger of injury. The lifting mechanism can be
damaged.
► Hold the torsion frame firmly when detaching the control rods from the
installation aids.
► Carefully fold down the torsion frame.

► Remove the pins between the control rods and the installation aids (see
Figure 16, page 37).
► Carefully fold down the torsion frame.
► Release the screw clamps with which the installation aids are fixed to the
vehicle chassis.
► Remove the installation aids from the vehicle.

7.3. Installation of the hydraulic unit

The installation of your hydraulic unit depends on the selected type. Four
types are available:
• Slide-in unit
• Turning unit
• Box unit
• Universal unit
The hydraulic unit is normally pre-assembled by PALFINGER Tail Lifts. On
request, you can also obtain a box unit with long cables and hoses. You can
mount this box unit at any position under the vehicle. In this case, bundle
cables and hoses that are too long and secure them under the vehicle.

45
 8. Establishing electrical connections

Note:
Observe the vehicle manufacturer's installation guidelines for the correct
design of the tail lift's power supply, especially for the taps of plus and
earth.
Please also refer to the PALFINGER Tail Lifts electrical circuit diagram
supplied. You will find a copy of the electrical wiring diagram on the
controller.

The following work is required:

• establish connection to vehicle battery (see chapter 8.1)
• establishing earth connections (see chapter 8.2, page 47)
• connecting the acoustical signal generator (see chapter 8.3, page 47).
• install and connect optional control unit (see chapter 8.4, page 48)
• attaching the control panel or Slimpanel (see chapter 8.5, page 50)
• connect optional hand cable switch (see chapter 8.6, page 52)
• connect optional remote control (see chapter 8.7, page 53)

8.1. Establishing the connection to the vehicle battery

Battery cable Main fuse Battery cable Main fuse

Figure 23: Battery connection

► Lay the positive battery cable to the battery or alternatively to the battery
distributor (fuse box). Shorten as required.
► Attach the cable lug to the battery cable.
► Attach the main fuse with the cable lug and connect the battery cable to
the battery plus terminal or alternatively to the battery distributor (see
Figure 23).
Optional:
► Run the earth cable to the battery or to an earth bolt on the chassis.
Shorten as required.

46
► Crimp the cable lug and mount it on the battery's minus terminal or on the
earth bolt on the chassis.
With vehicles with preinstalled ETMA interface:
► Plug the plus and minus cables into the mating plugs.

Note:
With hazardous goods vehicles, the ground cable must be connected to
the battery or in accordance with the vehicle manufacturer's guidelines for
mounting attachments.

Note:
We recommend installing a battery disconnect switch to be able to
disconnect the tail lift from the power supply in the event of a fault.

8.2. Establishing earth connection

If the earth cable is not directly connected to the battery, but the earth runs
over the vehicle chassis: Establish an earth cable from the cable lugs and
protective caps supplied.

Note:
Before connecting the ground cable, find out from the vehicle maker
whether this is possible.

► Cut off the required length of cable from the supplied battery cable.
► Keep the earth cable as short as possible and attach it to the ground screw
provided on the stand tube (see Figure 10, page 30, Pos. 8).

8.3. Connecting the acoustical signal generator

► According to the circuit diagram, connect the signal generator for the
acoustical warning signal that sounds when the platform lowers (optional).

47
 8.4. Installing and connecting the control unit / the
indicator light
The optional control unit must be mounted in a suitable location in the driver's
cab.
If a control unit is already present in the vehicle, you must connect your
PALFINGER Tail Lifts tail lift according to a special circuit diagram, which
you can obtain from PALFINGER Tail Lifts.

8.4.1. Control unit connection

Note:
Connection of the control device must not take place until the electrical
connection of the plus and minus cable of the hydraulic unit has taken
place.

► Run the cable for the control unit to the driver's cab.
► Select a suitable location on the dashboard in the driver's cab.
► Drill a hole Ø = 20.2 mm in the dashboard for the control unit (see
Figure 24).
► Provide the hole with a lug on the right-hand side (anti-rotation protection
for the control unit).

2,2 mm

11 mm

Figure 24: Hole for the control unit

► Establish an electrical connection as per the PALFINGER Tail Lifts circuit

diagram (see also Figure 25).

Y/GN BN

1 RD

Figure 25: Control unit connection

► Insert the control unit into the dashboard.

48
8.4.2. Indicator lamp connection
► Mount the PALFINGER indicator light in the driver's cab. This indicates
when the tail lift is not in the driving position (part no. 2067902, design of
the hole as for the control unit, connection in accordance with the wiring
diagram, see also Figure 26).
1
1/BL

2/BR
3

Figure 26: Indicator light connection

49
 8.5. Attaching the control panel or Slimpanel

Figure 27: Control panel with control panel holder

► Fix the control panel holder or weld it in position.

► Mount the control unit on the control unit holder.
Or:

Figure 28: Slimpanel with mounting brackets

► Fit the Slimpanel with the mounting brackets provided.

Alternatively:
► Fit the Slimpanel directly to the luggage compartment of the vehicle.

50
 Note:
When fitting the control panel and the Slimpanel, observe the requirement
of the EN 1756-1 standard for the distance of operating elements from the
end of the superstructure.
The distance L from the end of the superstructure to the centre of the
control panel or Slimpanel must be 300 to 600 mm (see Figure 29). The
operator must have an unobstructed view of the platform and the load
from the operating elements.

Figure 29: Slimpanel/control panel mounting position

51
 8.6. Connecting the manual cable switch (optional)
A manual cable switch or a radio remote control are optionally available for
your PALFINGER Tail Lifts tail lift.

Note:
When installing a manual cable switch, you must attach the cable with
socket under the vehicle loading area so that the cable can be connected
to the manual cable switch.

Cores Plug

Figure 30: Manual cable switch

Lead Pin Leads manual cable switch

for three buttons for two buttons
1 4 white -
2 5 green -
3 6 black yellow
4 3 yellow red
ye/gn 2 red green/black

► Select a suitable place for mounting the socket under the vehicle loading
bay. A fixing option is provided on most control panel holders.
► Mount the socket.
► Connect the cable from the socket in the terminal box in accordance with
the PALFINGER Tail Lifts circuit diagram.

52
 Note:
If the manual cable switch is on the attachment, this is not supplied with a
socket but is connected via a junction box with the wire from the controller.
The manual cable switch is then fixed and cannot be unplugged. The
required circuit diagram is available on request from PALFINGER Tail
Lifts.

► Find a suitable and secure storage location for the manual cable switch.
Attach the supplied mounting bracket there.
► Operation of the manual cable switch only permissible from the marked
position on the platform.

8.7. Radio remote control

PALFINGER Tail Lifts optionally offers the Remote Control BT radio remote
control (see Figure 31).

Figure 31: Remote Control BT

With a Remote Control BT, the recipient is already pre-assembled and only
needs to be connected to the controller and fitted to the vehicle.
The Remote Control BT radio remote control and the corresponding receiver
are matched to each other so that functionality is immediate.
► Observe the detailed assembly and operating instructions enclosed with
the Remote Control BT radio remote control.

53
 9. Installing and connecting the platform

WARNING!
Risk of injury and damage to property if the tail lift is operated without
a body!
If the tail lift is operated without a vehicle body or without a loaded
container, the lifting cylinder pistons can drive out of the cylinders. Risk of
injury due to sudden lowering of the lifting mechanism and platform; this
results in a risk of injury and of poisoning due to escaping hydraulic oil, as
well as danger to the environment.
► Only operate the tail lift with its body.

The following work steps are required:

• Positioning the platform with a lifting device on the vehicle (see
chapter 9.1)
• Bolting the platform to the control rod of the torsion frame (see
chapter 9.2, page 56)
• Bolting the platform to the tilt cylinders (see chapter 9.3, page 57)
• Adjusting the tilt cylinders (see chapter 9.4, page 60)
• Connecting the plug for the foot switch and Warnfix, fitting the tilt sensor
(see chapter 9.5, page 61)

54
9.1. Moving up and positioning the platform
► Raise the platform with suitable lifting equipment such as a forklift truck,
for example. Pad the lifting equipment with a suitable material to prevent
damage to the platform.
► Bring the platform to the rear of the vehicle.

Figure 32: Bringing the platform to the rear of the vehicle

► Move the platform to the mounting position at the rear of the vehicle.
► Maintain the installation position with the lifting equipment until the
platform is bolted to control rod and tilt cylinders.

55
 9.2. Bolting the platform to the control rod
► Make sure that the platform is in its final installation position.
► Bolt the cantilever heads of the platform to the control rods of the torsion
frame. Insert the spacers provided to align the platform centrally with the
superstructure (see Figure 33).

Note:
On a type C 750 S tail lift with a 550 control rod, you may only move the
platform by one disc from the centre.
You will find the type of control rod in the order confirmation.

Control rod

Cantilever head Cantilever head

Platform

Spacer discs Spacer discs

Figure 33: Spacer discs

► Push the pins through completely.

► Put the lugs on the pins. Use a hammer to knock in the lug as far as it will
go (see Figure 34, page 57).
► Turn the lug to the screw-on position. Bolt on the lug with the M12 bolt.
Observe the tightening torque of 75 Nm.

56
 Cantilever head

Bolt M12

Lug

Pin
Control rod

Figure 34: Pin, lug

9.3. Bolting the platform to the tilt cylinders

Depending on your tail lift model, you will need to bolt one or two tilt cylinders
to the platform.
► Loosen the hose clamps of the bellows on the tilt cylinders and slide the
bellows down (see Figure 35).

Bellows

Counter nut
Rod head

Clamp

Figure 35: Tilt cylinder

► Turn the rod ends of the tilt cylinders on the piston rods as far as they will
go (clockwise).

57
 ► Adjust the tilt cylinders’ length so that it possible to easily bolt the tilt
cylinders to the platform. Operation of the tail lift: see operating
instructions.
► During this procedure, hold the
• the tilt sensor B15 with the cable pointing downwards (not necessary
with the “Basic” controller) or
• the tilt sensor B15S vertically with the cable outlet to the right and the
snap-in bracket towards you.
Tilt sensors: see Figure 36.

Tilt sensor B15

Tilt sensor B15S

Figure 36: Tilt sensors

► Bolt the tilt cylinders to the platform. Insert the spacers provided to set the
cylinder flush with the control rods of the torsion frame.
► Push the pins through completely.
► Put the lugs on the pins. Use a hammer to knock in the lug as far as it will
go. Turn the lug to the screw-on position (see Figure 37, page 59).

58
Cantilever head

Bolt

Bottom roller
Lug

Pin

Tilt cylinder

Figure 37: Bolting the tilt cylinder

► Screw on the lug with the M12 bolts (Tightening torque: 70 to 75 Nm).
► Fit the bottom rollers and secure them on each pin/locking screw with a
snap ring (see Figure 38).

Snap ring

Bottom roller

Shims

Figure 38: Installing the bottom roller

► Before lifting the platform, ensure that the solenoid valves on the lift
cylinder have free access to the console plate pocket of the bolted console
(console plate pocket: see Figure 10, page 30, pos. 6). If necessary, turn
the coil on the solenoid valve to establish free travel.
► Move the lifting mechanism via the lift cylinder to the upper stop (see
operating instructions).
► Remove the lifting equipment from the platform.

59
 9.4. Adjusting the tilt cylinders

Note:
At the desired end position of the platform, the tilt cylinders must be
extended to the stop.

► Close the platform to the extent possible (see operating instructions). The
tilt cylinders are extended to the stop.
► Take the load off the tilt cylinders by opening the platform minimally.
► Move the platform to the desired end position. To do this, turn the piston
rod of the tilt cylinders with a wrench (see Figure 39).

Figure 39: Twisting the piston rod

► Repeat the adjustment process if required, until the platform has reached
the desired position.
► Release the tilt cylinders by opening the platform.
► Tighten the counter nuts of the piston rods (tightening torque:
250 to 300 Nm).
► Pull the bellows back over the piston rods.
► Secure the bellows with the hose clamps.

60
 9.5. Installing tilt sensors
Depending on the selected equipment, the tail lift is delivered with a tilt
sensor B15 or B15S (see Figure 36, page 58).

9.5.1. Installing tilt sensor B15

Figure 40 shows the cover cap with sensor holder for the tilt sensor B15 as
delivered with the tail lift. The cover cap is located on the underside of the
platform next to the right cantilever head. Depending on the equipment
version of your tail lift, connector plugs for warning lights and foot switches
come out below the cover cap.

Cover cap with

sensor holder

Connector plug

Figure 40: Cover cap with sensor holder for tilt sensor B15

► Unscrew the cover cap.

► Connect the cables for warning lights and foot switch to the existing
connector plugs.
► Place the connector plugs inside the platform.
► Reconnect the cover cap.
► Screw the tilt sensor B15 to the sensor holder of the cover cap as
presented in Figure 41, page 62, (tightening torque: 5 Nm).

61
 Cover cap with
sensor holder

Tilt sensor B15

Figure 41: Cover cap with tilt sensor B15

► Lay the cable of the tilt sensor B15 together with the cables for warning
lights and foot switch along the torsion frame. Make a loop for the cable
of the tilt sensor as strain relief.
► Attach the cables adequately to the torsion frame. Make sure that the
cables are laid so that they are free to move and are not stretched or
pinched when the tail lift moves.
► Connect the cables to the tail lift controller (see circuit diagram).

62
 9.5.2. Installing tilt sensor B15S
For the installation of the tilt sensor B15S, a platform connector is provided
on the underside of the platform next to the right cantilever head (see
Figure 42). The platform connector and the tilt sensor B15S are also used to
supply power to the electrical components of the platform.

Platform
connector

Dummy plug

Cantilever head

Figure 42: Platform connector

► Remove the dummy plug from the platform connector (see Figure 42).
► Insert the tilt sensor B15S into the platform connector until it clicks into
place (see Figure 43).

Tilt sensor B15S

Platform
connector

Figure 43: Installation of tilt sensor B15S

► Run the cable of the tilt sensor B15S along the torsion frame to the
controller.
Attach the cable sufficiently to the torsion frame. Make sure that the cable
is laid so that it is free to move and is not stretched or pinched when the
tail lift moves.

63
 10. Adjusting and testing installed tail lift
When you have installed your PALFINGER Tail Lifts tail lift, you must then
adjust it and test that it is functioning properly. This entails the following jobs:
• adjusting the tilt sensor B15 or B15S (B15: see chapter 10.1, page 64;
B15S: see chapter 10.2, page 65).
• adjusting the tilt switch B13 (see chapter 10.3, page 67).
• Bleeding the hydraulic cylinders (see chapter 10.4, page 68).
• on PTC 750 L, LLW: Checking alignment of the platform (see
chapter 10.5, page 69).
• Performing an oil level check (see chapter 10.7, page 71).
• Lubricating the bearing (see chapter 10.8, page 72)
• Checking bolted connections (see chapter 10.9, page 72).
• Checking hoses and cables (see chapter 10.10, page 72).
• adjusting the tilt cylinder (see chapter 10.11, page 73)
• Adjusting the pressure switch of the hydraulic support (optional, see
chapter 10.12, page 74).

10.1. Setting tilt sensor B15

DANGER!
Danger to life and material damage in case of improper adjustment of
tilt sensor B15!
If tilt sensor B15 is adjusted to a too steep inclination of the platform, the
load may roll off the platform. There is a risk of serious or fatal injury to
persons on the platform. Material damage may occur.
100° ► Adjust tilt sensor B15 so that the inclination of the platform is 100
degrees or less.

► Open the platform (see operating manual).

► Check the inclination of the platform.
If the inclination of the platform is more than 100 degrees:
► Adjust tilt sensor B15. To do this, use the slotted hole with which the tilt
sensor is screwed to the sensor holder.

64
 10.2. Adjusting tilt sensor B15S

DANGER!
Danger to life and material damage in case of improper adjustment of
tilt sensor B15S!
If tilt sensor B15S is adjusted to a too steep inclination of the platform, the
load may roll off the platform. There is a risk of serious or fatal injury to
persons on the platform. Material damage may occur.
100°
► Adjust tilt sensor B15S so that the inclination of the platform is 100
degrees or less.

Tilt sensor B15S can be adjusted by reprogramming it. To do this, proceed

as follows:
► Open the platform (see operating manual).
► Press one of the foot switches eight times.
► If there is no foot switch available: Give a plus pulse eight times to the
plug location J3, pin 6, on the controller (see Figure 44). To do this, you
can tap plus from the pin next to it.

Connector slot J41C Connector slot J3, plus pin

Connector slot J3, pin 6

7-segment display

Figure 44: Controller (example image)

The 7-segment display on the controller indicates “J” for adjustment. The
warning lights on the platform are lit up continuously. The current angle of
the platform was taken as the reference value.
► From this platform position, move to the desired correction angle.

65
 ► Press one of the foot switches eight times.
If there is no foot switch available: Give a plus pulse eight times to the
plug location J3, pin 6, on the controller. To do this, you can tap plus from
the pin next to it.
The 7-segment display on the controller indicates “0” or “1”. The warning
lights on the platform flash again. The new inclination of the platform is stored
as a correction value.

Note:
After 60 seconds without actuation, the adjustment mode is exited. Values
that are not saved are lost.

To remove the correction value again or set it to zero degrees:

► Press one of the foot switches eight times.
If there is no foot switch available: Give a plus pulse eight times to the
plug location J3, pin 6, on the controller. To do this, you can tap plus from
the pin next to it.
The 7-segment display on the controller indicates “J” for adjustment. The
warning lights on the platform are lit up continuously.
► Disconnect the 3-pole plug of the platform sensor J41C from the controller
(see Figure 44, page 65).
► Press one of the foot switches eight times.
If there is no foot switch available: Give a plus pulse eight times to the
plug location J3, pin 6, on the controller. To do this, you can tap plus from
the pin next to it.
The 7-segment display on the controller indicates “5”. The warning lights on
the platform flash again.
► Plug connector J41C back in.
► The 7-segment display on the controller indicates “0” or “1”. the correction
value is deleted.

66
 10.3. Setting tilt switch B13

Note:
If the tilt sensor B15 is present on the torsion frame of your tail lift, there is
no need to set the tilt switch B13.

► Move the platform to the position horizontally approx. 250 mm above the
ground as presented in Figure 45, page 67.

approx. 250 mm
Tilt switch B13

Figure 45: Tilt switch B13 (1)

► Release the screw on tilt switch B13 on the right control rod of the torsion
frame (see Figure 46).

Safety plate

Bolt

Tilt switch B13

Figure 46: Tilt switch B13 (2)

► Adjust tilt switch B13 so that it is exactly horizontal.

► Retighten the screw on tilt switch B13. Observe the tightening torque of
9 Nm.
► Edge the safety plate over the control rod of the torsion frame so that tilt
switch B13 is secured in position.

67
 10.4. Bleeding the hydraulic cylinders
To bleed the hydraulic cylinders of the tail lift:
► Switch on the tail lift (see operating instructions).
► Raise and lower the platform several times. Load the platform with the
nominal load.
► Open and close the platform several times.
► Extend and retract the hydraulic props several times (optional).

Note:
Special procedure for bleeding the hydraulic cylinders when the distance
between the lifting mechanism and the ground is small.
► Proceed as described in chapter 10.5, page 69, if the distance from the
lifting mechanism to the ground is small (dimension "G" from the centre
of the stand tube/linkage mount to the ground is less than 450 mm, see
Figure 47).

Stand tube Linkage mount

G G

Figure 47: Distance between the lifting mechanism and the ground (dimension
"G")

68
10.5. Bleeding the hydraulic cylinder (G < 450 mm)
Special procedure if the distance between the lifting mechanism and the
ground is small (dimension "G" from the centre of the stand tube/linkage
mount to the ground is less than 450 mm, see Figure 47, page 68):
► Raise the rear of the vehicle, for example by driving the rear wheels onto
ramps.
► Switch on the tail lift (see operating instructions).
► Open the platform until it is approx. 90 degrees open.
► Lower the platform.
Once the platform is about halfway down:
► Open the platform further so that its top slopes further down.
► Lower the platform completely.
► Close the platform completely again.
► Repeat this procedure two to three more times.
► Close the platform completely again.
The hydraulic cylinders are bled.

69
 10.6. Checking alignment of the platform
(only PTC 750 L, LLW)
► Move the platform horizontally to the end stop of the case and then back
again a few millimetres.
► Position the platform parallel to the end stop using the adjusting screw on
the tilt link (see Figure 48).

Adjustment screw Tilt link

Bolted connection
Underrun protection
Figure 48: Tilt link, PTC 750

► Tighten the bolted connection between the underrun protection and the
tilt link.
► Now check that the platform stops on both sides simultaneously.
► Repeat the steps to align the platform if this is not the case.

70
 10.7. Performing an oil level check
10.7.1. Slide-in unit
To check the oil level:
► Lower the tail lift so that it rests on the ground (see operating instructions).
► Retract existing support feet.
► Open the right cover of the stand tube.
► Loosen the fixing bolt of the hydraulic unit on the stand tube.
► Pull out the hydraulic unit until the oil level in the oil tank is visible (see
Figure 49).

Controller

Stand tube
Oil tank
Hydraulic pump
Electric motor

Figure 49: Hydraulic unit

► Check the oil level in the oil tank.

The oil tank should be about ¾ full when the tail lift is in this position.
► Close the platform.
► Fully extend existing support feet.
► Check the oil level in the oil tank again.
There should still be a level of oil in the oil tank when the tail lift is in this
position so that the oil pump cannot suck in air when the platform is closed.
► If necessary, top up with hydraulic oil (recommended hydraulic oils: see
chapter 10.7.3, page 72).
► Slide the hydraulic unit back into the stand tube
► Fix the hydraulic unit with the fixing bolt.
► Close the right cover of the stand tube.

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 10.7.2. Box, universal or turning unit
To check the oil level:
► Remove the cover of the unit.
► Proceed as described in the previous chapter for slide-in units.

10.7.3. Recommended hydraulic oils

• Shell Tellus S2 V 15
Operating temperature: -20 °C to 60 °C
• Aero Shell Fluid 41
Operating temperature: -54 °C to 90 °C
• Special “cold” configuration:
Aero Shell Fluid 41 and cryogenic seals against glazing of the sealing
materials
Operating temperature: down to -54 °C

10.8. Lubricating the bearing

► Using a grease gun, press grease into the tapered grease nipples of all
bearing points of the hydraulic cylinder bearings and the control rod
bearings. Press grease into it until it comes out at the side of the
respective bearing point.
A tail lift with two hydraulic cylinders has eight bearing points. A tail lift with
four hydraulic cylinders has twelve bearing points.
Recommended grease: Shell Gadus.

10.9. Checking bolted connections

► Take the required tightening torques of the bolted connections from the
attachment report (attachment drawing) and the tables on page 31 and
page 42.
► Make sure that all bolted connections are secure.

10.10. Checking hoses and cables

► Check that all hoses are free from damage.
► Check that all hoses move freely and are laid so that they cannot be
damaged by movements of the tail lift or vehicle.
► Check all cables for external damage.
► Check that all cables are adequately secured and laid so that they cannot
be damaged by movements of the tail lift or vehicle.

72
10.11. Adjusting the pressure relief valve
► Adjust the pressure relief valve so that the tail lift cannot lift more than
125% of its maximum load (see Figure 50).

Note:
For adjustment of the pressure relief valve, observe the chapter “Test by
the assembler after assembly" in the control booklet.

► Seal the pressure relief valve.

Pressure relief valve

Figure 50: Pressure relief valve on the hydraulic unit

73
 10.12. Adjusting the pressure switch of the hydraulic
support (optional)

If the hydraulic support raises the vehicle too high or the props do not reach
the ground, adjust the pressure switch of the support.
► For this purpose, turn the grub screw on the pressure switch (see Figure 51).

Grub screw

Pressure switch

Hydraulic support

Figure 51: Hydraulic support, pressure switch

► To decrease the contact pressure of the props, turn the grub screw anti-
clockwise one rotation.
► To increase the contact pressure of the props, turn the grub screw
clockwise one rotation.
► After adjusting the contact pressure, check the adjustment by lowering the
props. If the desired shut-off of the support is not provided, repeat the
adjustment.

74
 11. Final work
11.1. Attaching warning strips and type plate
The scope of delivery of all PALFINGER Tail Lifts tail lifts includes two
warning strips. The warning strips are mounted according to the enclosed
"Assembly instructions for warning strips" (drawing no. 92-597.99-00.00-00).
► Mount the warning strips according to the enclosed assembly instructions
on the PALFINGER Tail Lifts tail lift.
► Clean and degrease the designated area for the type plate on the
platform, e.g. with silicone remover.
► Glue the supplied type plate to the platform (see Figure 52, page 75).

Type plate

Figure 52: Type plate

► Glue the test plaque on a prominent place.

75
 11.2. Performing acceptance test as per control booklet
► Perform initial commissioning in accordance with the control booklet.
► Enter the required details in the control booklet:
• Company
• Code
• Installation company
• Details of signatory
► It is essential that you enter the details on the operator and vehicle as well
as the form “Confirmation by the installation firm” in the control booklet.

Note:
The control booklet as well as the further documents from the
PALFINGER document pouch (operating manual, short operating manual,
attachment report, certificates) should always be kept in the vehicle.

76
 12. Hydraulic diagrams

12.1. Standard tail lift with four cylinders

TILT CYLINDER LIFT CYLINDER LIFT CYLINDER TILT CYLINDER

Figure 53: Hydraulic diagram, 96-560.98-00.00-00

77
 12.2. Standard tail lift with soft levelling

TILT CYLINDER LIFT CYLINDER LIFT CYLINDER TILT CYLINDER

TILT LOCK

Figure 54: Hydraulic diagram, 18-587.98-01.00-03

78
12.3. Standard tail lift with two cylinder

TILT CYLINDER LIFT CYLINDER

Figure 55: Hydraulic diagram, 97-510.98-00.00-00

79
 12.4. Standard tail lift with hydraulic stabilizer feet

TILT LIFT LIFT TILT

CYLINDER CYLINDER CYLINDER CYLIND
ER

Figure 56: Hydraulic diagram, 96-524.98-01.00-00

80
 12.5. Tail lift with hydraulic stabilizer feet C 750 L

TILT CYLINDER LIFT CYLINDER

STABILIZER FEET
CYLINDER

Pressure switch S8.1

adjusted to 20 bars

Figure 57: Hydraulic diagram, 12-530.98-01.00-00

81
 12.6. Tail lift with hydraulic stabilizer feet C 750 S

TILT LIFT LIFT TILT

CYLINDER CYLINDER STABILIZER FEET CYLINDER CYLINDER
CYLINDERS

Pressure switch S8.1

adjusted to 50 bars

Figure 58: Hydraulic diagram, 08-531.98-01.00-00

82
 12.7. Standard tail lift with hydraulic underrun bumper

TILT CYLINDER LIFT CYLINDER LIFT CYLINDER TILT CYLINDER

Figure 59: Hydraulic diagram, 99-514.98-01.00-00

83
 PALFINGER Tail Lifts GmbH
Fockestraße 53
D-27777 Ganderkesee/Hoykenkamp
Tel.: +49-4221 8530
Fax: +49-4221 87536
infombb@palfinger.com
www.palfinger.com

PALFINGER Hayons S.A.S.

Rue de l‘Eglise
F-61310 Silly en Gouffern
Tel.: +33-2 33 12 44 00
Fax: +33-2 33 12 44 01
francembb@palfinger.com
www.palfinger.com

PALFINGER Tail Lifts s.r.o.

Gogolova 18
SK-85101 Bratislava
Tel.: +421-252 636 611
Fax: +421-252 636 612
mbbsk@palfinger.com
www.palfinger.com

PALFINGER Tail Lifts Ltd.

2 Falcon Gate, Shire Park
Welwyn Garden City
Herts., UK, AL7 1TW
Tel.: +44-01707 325571
Fax: +44-01707 327752
customer.services@palfinger.com
www.palfinger.com